FC Explorer 8.8 Diff Kit

[largeorangefont]

Hmmm. the seller said its from an 05 exploder. He explained they changed the case design in 05 or 06 to the dual mount....Is this accurate?

They changed the case to dual front mounts in 06. I have a case from an 05 Aviator in my car and it is the single mount. If it is an 05 you are getting, you should be fine.

I have not personally measured the front mounting pattern for the dual mount Explorer diffs so I am not 100% certain but I doubt Ford just "added" a mount to the driver side of the diff and left everything else the same with the 06 Explorer case revision. The IRS Cobra diff housing with its dual front mount is entirely different in size and positioning than the Explorer housing.

[onefastrx7turbo]

I better take some pictures when I get home to verify. I'm getting nervous now....

[largeorangefont]

Guys,

Just wanted to share what I had made up this week. I'm running solid subframe and rear diff mounts with my Ronin 8.8 kit and wanted a solid spacer for the front diff mount to keep the front of the diff from moving. I am still using the Explorer rubber front diff mount, but these spacers should keep the diff pretty well captured with the Ronin mounting hardware.

These are made from 2" diameter alumnium with a 1" hole in the center. I had 3 spacers made, each with a different bevel to set the pinion angle (I was not 100% sure what angle I needed) They are 1, 1.5, and 2 degrees, with the thin side of all the spacers being 3/8".

I will post which one worked the best once I get them installed this weekend.

[onefastrx7turbo]

Nice spacers largeorangefront! Here are the pics of my diff. Sorry they are crappy Iphone pictures.

[largeorangefont]

Ok will that is definately an 06+ Explorer case.. maybe they did just add a mount to the drivers side. Measure from the pinion center line to the passenger mount centerline. Also measure from the front of the pinion flange to the passenger mount centerline.

One of us can compare to see if it is close or even the same. Youll still have to lop off that entire driver side mount. Not sure if you want to do that or get another case.

[onefastrx7turbo]

I'll measure it this weekend. I got the whole thing for $325. It's been rebuilt by a local ford tech with new bearings, seals, 3.55 gears, etc. everything inside is new...Id hate to let it go...

[frijolee]

One of the few parts of this installation that can prove to be a bit challenging is pulling off your donor outer CV's.  A few folks have run into an axle that just proved stubborn (it's been maybe one guy in five).   I wanted to come up with a way to kick ass and take names just in case other folks had the same problem that was a little more elegant than big hammers (even nice brass ones).

So I made a tool...

Finished split ring on the left started life as the bit on the right.


Daddy's little helper.  Bottom half clamped to the axle.


24 tons of bottle jacks, something going to give.  Split rings push directly on the inner race.  Top half is a slip fit.


Not a problem.


Like I said, usually you can find the direction the ring wants to sit and it'll just pop free.  In this case we couldn't get it to seat right and we pushed hard enough that it tore some of the splines off the axle.


If you get stuck, hit me with a PM or email to roninspeedworks@gmail.com and we'll do it for you. 

-Joel (for the Ronin)

[digitalsolo]

Holy crap, haha.   Me = fan of overkill. 

[largeorangefont]

Mine is all in for the final time. I ended up using the 1.5 degree spacer to get the pinion angle where I wanted it.

Also I weighed the assembled hybrid halfshafts against the TurboII halfshafts. The hybrid halfshafts are about 4 lbs heavier each. That makes the weight difference about a wash for this swap.


Plenty of thread contact with Turbo 626 outers and no washer. Axle is flush with the nut.


Looking down the back of the hub, you can see where the boot clamp sticks out. The DTSS bushing is already beveled and the clamp clears.


Basically ready to go. I ended up needing a slightly longer sublink (about 1/4 inch) with my solid front mount spacer. I installed a Ground Control unit today and it fits great with plenty of clearance around the diff housing. I also installed the small CV boot clamps after I took this. I removed the axle seal covers from the Explorer inner CVs. I don't plan on taking the car out in the mud or dirt so I figure those weren't needed.


Soild spacer installed


Driveshaft clearance - the weight is about 1/4 in from the subframe - Whew that was close


Mustang pinion flange and yoke clearance

[IFRYRCE]

More like a close up of right here.  How much did you have to trim the front diff mount or the subframe in front of it?  Mine are touching right now and I am planning to do some clearancing at work later.

I notched the subframe in front of the front diff mount and welded in a patch today.  Now I have a small gap between the subframe and the diff mount.


I also skimmed about a 2-3 degree angle on the tops of my MMR delrin diff mounts to get the nose up a bit which seemed to help a lot.  I had already slightly elongated the holes as largeorangefont said he had to do but that didn't seem to be enough.

Okay, cool, so I am not the only one facing this. Just ran into it today in the garage, will try and deal with it tomorrow.

[onefastrx7turbo]

Ok, I hope I measured the correct places. How do these measurements look?

[lt1fc3s]

just ordered the kit for my auto lt1 fc. 3.55 gears, and it will be welded. yes welded

[onefastrx7turbo]

Can Ronin verify if those measurements are the same as the single mount cases?

[MoparX]

Largeorangefont:

What u-joints did you wind up with?

[largeorangefont]

Largeorangefont:

What u-joints did you wind up with?

I believe they are 1310s. I bought Bowtie7's driveshaft when he swapped his out for a carbon fiber shaft. He had it shortened and rebalanced for the Ronin engine mounts.

I am not drag racing, so I think the 1310s will be fine.